Segmented Stator Module for Planar Drive Energy Reduction

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Solution Overview

Problem

Existing planar drive systems face challenges in efficiently driving rotors in multiple independent directions with minimal energy consumption and heat loss, while maintaining a compact magnet arrangement and reducing the number of simultaneously energized stator segments.

Innovation Solution

The stator module is designed with a segmented stator assembly comprising independently energizable stator sectors, where each sector has elongated conductor strips that interact with magnet units, allowing for precise adjustment of the energized area to match the magnet arrangement, reducing unnecessary energization, and optimizing the number of simultaneously energized segments to minimize energy consumption and heat loss.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If the stator comprises a large number of conductor strips arranged in a grid pattern, then the rotor can be driven in multiple independent directions, but the number of simultaneously energized stator segments increases, leading to higher energy consumption and heat loss

Engineering Contradiction:

Improvemulti-directional rotor movement capabilityVSAvoidenergy consumption

Core Design Contradiction:

Adaptability or versatilityVSUse of energy by moving object

Solution Approach 1:

The stator is divided into multiple independently controllable stator segments, each comprising conductor strips that can be selectively energized. This segmentation allows only the segments adjacent to the rotor to be activated at any given time, reducing the total number of energized segments while maintaining multi-directional movement capability

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of energizing the entire stator surface, only the partial area corresponding to segments adjacent to the rotor is activated. This partial action approach minimizes energy consumption and heat loss while still achieving the required multi-directional rotor control

Inventive Principle:

Principle #16Partial or excessive action

2Adaptability or versatility

If the stator comprises a large number of conductor strips arranged in a grid pattern, then the rotor can be driven in multiple independent directions, but the heat loss increases due to simultaneous energization of multiple segments

Engineering Contradiction:

Improvemulti-directional rotor movement capabilityVSAvoidheat loss

Core Design Contradiction:

Adaptability or versatilityVSLoss of energy

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different stator segments are energized in periodic sequences as the rotor moves between positions. This periodic activation pattern ensures that heat generation is distributed over time and space, preventing excessive heat accumulation while maintaining continuous multi-directional control

Inventive Principle:

Principle #19Periodic action

3Adaptability or versatility

If the magnet arrangement is extended to cover a large area, then multiple rotors can be positioned independently, but the overall system size and complexity increase

Engineering Contradiction:

Improvemulti-rotor positioning capabilityVSAvoidstator area

Core Design Contradiction:

Adaptability or versatilityVSArea of stationary object

Solution Approach 1:

The stator is divided into multiple independently controllable stator segments arranged in a modular fashion. This segmentation allows the system to support multiple rotors by activating only the segments adjacent to each rotor, thereby achieving multi-rotor positioning capability without requiring a proportionally large increase in total stator area

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The segmented stator structure serves multiple functions: it provides independent control for multiple rotors, reduces the active area required at any given time, and maintains a compact overall system footprint through efficient space utilization

Inventive Principle:

Principle #6Universality (Multi-functionality)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This configuration enables efficient rotor movement in multiple directions with reduced energy requirements, minimized heat loss, and a compact magnet arrangement, allowing for closer proximity of multiple rotors without interference.

Implementation Method 1

a driving force is exerted on the rotor by current-carrying conductors magnetically interacting with drive magnets of a magnet arrangement

Methodology Applied

Scientific EffectElectromagnetic interaction: Lorentz Force

Data Source

PatentUS11437902B2Stator module and planar drive system

Publication Date: 2022.09.06 BECKHOFF AUTOMATION GMBH

AI summary

A stator module for two-dimensionally driving a rotor having first and second magnet units comprises a stator assembly including first and second stator segments for interacting with drive magnets of the first and second magnet units. The individual stator segments may each be energized independently from the remaining stator segments. The stator assembly comprises first, second, third and fourth stator sectors. The first stator segments of the individual stator sectors each extend in a second direction over all second stator segments of the relevant stator sector arranged side by side, and the second stator segments of the individual stator sectors each extend in a first direction over all first stator segments of the relevant stator sector arranged side by side. Extensions of the stator sectors in the first and second directions are respectively smaller than extensions of a magnet arrangement comprising the magnet units.